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# State of The Industry Ward Atkinson January 21, 20102 

# Activity  

## The refrigerant issue  

### R - 134a  

### HFO - 1234yf  

## The lubricant issue  

## SNAP Activity  

### Retrofitting R - 134a fleet  

### Replacement refrigerants3 

# State of Minnesota Regulatory Activity  

## Effective January 1, 2009 Report New Vehicle Mobile A/C R - 134a Emissions (SAE J2727)  

## 2009 MY Average single evaporator system refrigerant loss: (Average of A/C systems offered by vehicle product line)  

### 2.3% 14.1 Grams (0.49 ounce) per year  

## 2009 MY Average multi - evaporator system refrigerant loss: (Average of A/C systems offered by vehicle product line)  

### 1.9% 18.3 Grams (0.64 ounce) per year4 

# Service Issues R - 134a  

## Systems have less refrigerant leakage  

### Will require less service  

## System refrigerant charges are less  

### Knowing amount of system charge is critical  To assure proper system operation:
 Refrigerant removal and recharge is required
 “ Top off ” service is not acceptable 

###  

## New Service Equipment meeting SAE J2788 standard will reduce emissions and improve charging accuracy5 

# New Refrigerant HFO - 1234yf  

## HFO - 1234yf  

### System operating pressures are similar to an R134a system  

### It is mildly flammable  Work area must have proper ventilation  Handling and storage of cylinders must meet OSHA requirements  

### High energy required for ignition  Very few vehicle sources will ignite refrigerant  Open flame will ignite6 

# New Refrigerant HFO - 1234yf  

## New Service Equipment [J2843 – J2851]  

## New Technician Certification HFO - 1234yf [J2845]  

### Safety Issues  Refrigerant handling  

### OSHA Requirements  Workspace  Handling and storage of containers  

### Proper Service Procedures7 

# New Refrigerant HFO - 1234yf  

# State Use Regulations  

## Flammability  

# System refrigerant contamination issues  

## Effects are unknown when mixing R - 134a and other SNAP listed refrigerants with HFO - 1234yf8 

# HFO - 1234yf Systems
 

### System Components  Most R - 134a hose and seal materials are compatible with HFO - 1234yf systems  

### Lubricant compatibility  PAG with different additives for belt driven compressors  Carry over POE for electric compressors  

### Mixing of HFO1234yf and R - 134a  Should not be mixed due to mild flammability  Oils for HFO1234yf and R134a are similar but mixing impact is unknown9 

# HFO - 1234yf Systems

 

## HFO - 1234yf System Differences  

### New Compressors  Control of oil circulation  

### Potential addition of Internal Heat Exchanger between high and low side in plumbing  

### New Service Fittings10



## HFO - 1234yf Refrigerant Charging  

## Systems will minimize refrigerant charge  

### Knowing amount of system charge is critical  

### Overcharging may result in safety and performance concerns  

## Systems will have less refrigerant leakage  

### Will require less service  

## No “ Top off ” refrigerant charging!!!!!!  

### Refrigerant removal and proper charge is required11



## New standards for HFO - 1234yf  

### J2843 Recovery/recycle- Recharge required  Flammability issues  System operation and performance  J2851 for recovery only  J2888 covers service hoses  

### J2911 requires certification of equipment, components, and technician training  

### J2912 refrigerant identifiers  

### J2913 Leak Detector  Some HFC - 134a leak detectors may not Identify HFO - 1234yf12 

# Lubricant Issue Hybrid Vehicles with HV Electric Compressors ...  

### System oil charge can not exceed 1% oil cross contamination  PAG reduces POE’ s resistivity (following slides)  Vehicle’ s HV Isolation may be compromised  Loss Of Isolation may set Diagnostic Trouble Code’ s  No Sealants – performance enhancement chemicals – flushing solvents should be used in the system  

### Presently use dedicated refrigerant charge equipment to insure prevention of oil cross - contamination [hose residue]  No oil or dye injection  

### SAE J2788 - H Recovery/recycle charge ... is developed  Requires refrigerant delivery with < 0.1% (1000ppm) cross contamination  

### Service Equipment Not allowed to have oil or dye injection capability13 Inverter U V W

Refrigerant Positive Terminal Negative Terminal

Like Capacitor which refrigerant become the conductor

Motor 3 phase terminals A (500V) 

# Electric Compressor14 14 Static Resistance measured between HV terminal and Compressor Ca se w/ DC500V Mega -tester (full liquid condition) 

# Electric Compressor

ND11 = POE

ND8 = PAG

# Field Coupled Hose Assemblies

 

# Covered by revised SAE J2064  

## Updated to cover both HFO - 1234yf and R - 134a  

## Certification required

1516 

# R - 134a and HFO - 1234yf Refrigerant Identification
 

### SAE J2912 Establishes specifications to identify relatively pure refrigerant HFC 134a (R - 134a) and HFO - 1234yf (R - 1234yf) from mixtures of refrigerants (HFC, HCFC, CFC, hydrocarbons, etc.)  In a refrigerant supply tank, or MAC system prior to recovering/recycling the refrigerant or prior to charging an A/C system from a refrigerant container  The identifier also must identify and display volume of non - condensable gases, such as air17 

# HFO - 1234yf Leak Detectors
 

## SAE J2913 Establishes requirements for identification of HFO - 1234yf an A2 flammable refrigerant
 

## Standard establishes minimum performance criteria for a modern class of electronic probe-type leak detectors18 

# HFO - 1234yf Recovery Recycle Charging Equipment


# – J2843
 

### Ventilation of Equipment Enclosure  2 Intake grills to maintain 6 air change per hour flow to maximize cross flow within the cabinet  

### Equipment Operating Performance Expectations  

### The equipment will have a  vacuum decay leak check  followed by a partial pressurization and pressure decay leak test  

### The MAC system cannot be charged without successfully completing both leak tests19 

# HFO - 1234yf Recovery Recycle Charging Equipment


# – J2843
 

### When in a deep vacuum mode if a system leak is greater than an equivalent of 0.3 grams/second the charging procedure will be locked out and prevent charging refrigerant  This leak rate is more than a typical evaporator corrosion leak  This method cannot be used for determining if the system has an evaporator leak  

### With the system evacuated to at least minus 675 mm. Hg. (minus 26.6 in Hg) and in the holding mode for 5 minutes if the pressure rise is more than 15 mm. Hg (26 in Hg) the system cannot be charged20 

# HFO - 1234yf Recovery Recycle Charging Equipment


# – J2843  

### Upon passing steps 1 & 2 10% of the programmed system charge is installed in the system  The pressure shall not decay more than 10% in 5 minutes  

### If more than a 10% pressure decay  Equipment will lock out all operation except recovery and evacuation  

### The user will be alerted to recover and check for a leak  System leak detection can be accomplished with this limited charge21 

# New Vehicle Labels  SAE J639 Safety Standards for Motor Vehicle Refrigerant Vapor Compression Systems 

## R - 134a HFO - 1234yf

J2842 Certification for OEM Mobile Air Conditioning Evaporator and Service Replacements J2845 Technician Training for Safe Service and Containment of Refrigerants22 

# New System Design Requirements [HFO - 1234yf]  

## Refrigerant leakage into passenger compartment  

## SAE J2842 Certified New and Replacement Evaporator Assemblies  

### Corrosion and structure requirements23



## J2842 Certification for OEM Mobile Air Conditioning Evaporator and Service

Replacements  

## For Safety  

### Leaking evaporators shall only be new  No evaporator repairs are allowed  No evaporators can be used from another system [no salvage or scrap systems]  

### All replacement evaporators shall be certified to meet SAE J2842  Includes all OEM and Aftermarket replacements  Have the required certification label24



### SAE J2911 Certification Requirements For System Components, Service Equipment and Technicians  

### Certification provides a means to assure a customer or Regulatory Agency  That the equipment delivers the advertised performance  Testing can be done by Manufacturer or laboratory  That the technician use recommended procedures for service and repair of MAC systems  Testing can be done by a qualified organization  

### SAE RESPONSIBILITY  Maintain a public Data Repository of the certification data submitted  

### Each Standard has appropriate certification requirements

# SNAP Activity

 

### Retrofitting of R - 134a fleet to another SNAP refrigerant  No Industry or SAE Standards  No recovery of recycle equipment  Potential for system contamination and failures of polymers [hoses – seals]  

### R - 12 fleet retrofitted to a SNAP refrigerant was less than 15% [MACS Filed Surveys]  38% of retrofitted system did not meet EPA 609 requirements  Service fittings – pressure switches – labels were installed

# SNAP Refrigerants
Refrigerant Cost 2009 vs. 1997

$0 $5 $10 $15 $20 $25

FRIGC FR-12 FREEZONE RB-276 GHG-X-4

#AutoFrostChill-It R414A ICOR #Hot

ShotKar KoolR-414B Freeze-12 GHG#McCoolR406A R-134a R-12

RefrigerantsCostperpound(Wholesalevolume)

2009 1997 HFO - 1234yf
Other SNAP Listed refrigerants R - 134a R - 12 Cost over 12 years

# SNAP Activity

 

## Use of SNAP refrigerants in HFO - 1234yf systems  

### HFO - 1234yf availability  

### HFO - 1234yf cost  

### No Industry or SAE Standards  

### Potential for system contamination and failures of polymers [hoses – seals]  

### Lubricant compatibility  

### System cooling performance28